Enhancing Precision in Arc Welding Simulations: A Comprehensive Study on Ellipsoidal Heat Source Model

Arc welding is a complex multi-physics process, and its finite element simulation requires significant computational resources to determine temperature distributions in engineering problems accurately. Engineers and researchers aim to achieve reliable results from finite element analysis while minimizing computational costs. This research extensively studies the application of conventional ellipsoidal heat source formulation to obtain improved temperature distribution during arc welding for practical applications. Approximated ellipsoidal heat source model, which artificially modifies the coefficient of thermal conductivity in the welding pool area to simulate stirring effects, (Modified Ellipsoidal Model) is shown to be scientifically valid by comparing its results with those of Comsol's multi-physics arc welding models. The results show that, in comparison to the conventional ellipsoidal model, the temperature distributions obtained using the modified ellipsoidal model closely approach those from multi-physics simulations. In particular, the temperature history in the middle of the weld pool significantly changes and approaches the multiphysics solutions. Additionally, several points near the heat-affected zone were analyzed, and both ellipsoidal methods produced similar temperature histories until the metal melted. After melting, the modified ellipsoidal method gradually aligns more closely with the multiphysics solution. Additionally, both ellipsoidal methods produce similar temperature histories at points within the heat-affected zone.